Classifications

• • C—CHEMISTRY; METALLURGY
  • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
  • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
  • C04B26/00—Compositions of mortars, concrete or artificial stone, containing only organic binders, e.g. polymer or resin concrete
  • C04B26/02—Macromolecular compounds
  • C04B26/10—Macromolecular compounds obtained otherwise than by reactions only involving carbon-to-carbon unsaturated bonds
  • C04B26/18—Polyesters; Polycarbonates
• • C—CHEMISTRY; METALLURGY
  • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
  • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
  • C04B26/00—Compositions of mortars, concrete or artificial stone, containing only organic binders, e.g. polymer or resin concrete
  • C04B26/02—Macromolecular compounds
  • C04B26/10—Macromolecular compounds obtained otherwise than by reactions only involving carbon-to-carbon unsaturated bonds
  • C04B26/14—Polyepoxides
• • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
  • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
  • Y02W—CLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO WASTEWATER TREATMENT OR WASTE MANAGEMENT
  • Y02W30/00—Technologies for solid waste management
  • Y02W30/50—Reuse, recycling or recovery technologies
  • Y02W30/91—Use of waste materials as fillers for mortars or concrete

Definitions

• This invention relates to polymer concrete compositions and their use in preparing articles.
• PIC polymer- impregnated concrete
• PPCC polymer-portland cement concrete
• PC polymer concrete
• acrylate resins especially methyl methacrylate.
• acrylate resins are relatively inexpensive, however, they suffer a multitude of serious shortcomings. For example, they exhibit high volatility, high toxicity, high flammability, and are explosive. More importantly, they exhibit high shrinkage which severely limits their useful life in some applications.
• a curable polymer concrete composition comprising:
• the vinyl ester resins which are preferred for use in compositions of the invention are those prepared by esterifying an epoxy resin containing at least one vicinal-epoxy group in the molecule with an ethylenically unsaturated carboxylic acid.
• Suitable epoxy resins containing at least one vicinal epoxy group, i.e. at least one group may be saturated or unsaturated, aliphatic, cycloaliphatic, aromatic or heterocyclic and may be substituted if desired with non-interfering substituents such as halogen atoms, hydroxyl groups and ether radicals. They may also be monomeric or polymeric.
• polyepoxides for clarity, many of the polyepoxides and particularly those of the polymeric type are described in terms of epoxy equivalent values. The meaning of this expression is described in U.S. Patent No. 2,633,458.
• the polyepoxides used in the present process are those having an epoxy equivalency greater than 1.0.
• liquid polyepoxides that may be used in the process of the invention are given in U.S. Patent No. 2,633,458, and other suitable polyepoxides are disclosed in U.S. Patent No. 3,377,406 and U.S. Patent No. 3,420,914.
• Preferred polyepoxides are the glycidyl polyethers of polyhydric phenols and polyhydric alcohols, especially the glycidyl polyethers of 2,2-bis(4-hydroxyphenyl)propane.
• glycidyl polyethers of 2,2-bis(4-hydroxyphenyl)-propane have an average molecular weight between about 300 and 3,000 and an epoxide equivalent weight between about 140 and 2,000.
• suitable epoxy compounds include those compounds derived from polyhydric phenols and having at least one vicinal epoxy group wherein the carbon-to-carbon bonds within the six-membered ring are saturated. Examples of such saturated epoxy resins are described in U.S. Patent No. 3,336,241. Preferred saturated epoxy resins are the hydrogenated glycidyl ethers of 2,2-bis(4-hydroxyphenyl)propane, sometimes called the diglycidyl ethers of 2,2-bis(4-cyclohexanol)propane.
• the ethylenically unsaturated carboxylic acid used to esterify the polyepoxide may be aliphatic, cycloaliphatic or aromatic and may be monocarboxylic or polycarboxylic.
• acids to be utilized comprise ethylenically unsaturated acids, such as acrylic acid, methacrylic acid, crotonic acid, alpha-phenylacrylic acid, alpha- cyclohexylacrylic acid, maleic acid, alpha-chloromaleic acid, tetrahydrophthalic acid, itaconic acid, citraconic, fumaric acid, cyanoacrylic acid and methoxyacrylic acid; and partial esters of polycarboxylic acids, and particularly the alkyl, alkenyl, cycloalkyl and cycloalkenyl esters of polycarboxylic acids, such as allyl hydrogen maleate, butyl hydrogen maleate, allyl hydrogen phthalate, allyl hydrogen succinate, allyl hydrogen fumarate, butenyl hydrogen tetrahydrophthalate, cyclohexenyl hydrogen maleate, and cyclohexyl hydrogen tetrahydrophthalate; and mixtures thereof.
• acids such as acrylic acid
• Monocarboxylic ethylenically unsaturated carboxylic acids such as acrylic or methacrylic acid are particularly preferred.
• any pendant hydroxy groups on the vinyl ester resins may, if desired, be reacted with an acid anhydride, preferably a polycarboxylic acid anhydride such as maleic anhydride.
• any known unsaturated polyester may in principle be employed in the polyester compositions.
• the basic technology for the manufacture of unsaturated polyesters is well established. Simply, such unsaturated polyesters may be prepared by either the fusion or solvent process wherein saturated and/or unsaturated polycarboxylic acids and/or anhydrides are poly- esterified e.g. with polyhydric alcohols (glycols) or alkylene oxides.
• Suitable carboxyl-containing compounds include the saturated and unsaturated aliphatic, aromatic and cycloaliphatic polycarboxylic acids and polycarboxylic acid an- hydrode, which compounds may be substituted e.g. with halogen atoms.
• Typical such carboxyl-containing compounds are maleic acid, maleic anhydride, crotonic acid, itaconic anhydride, tetrahydrophthalic acid, fumaric acid, phthalic anhydride isophthalic anhydride, terephthalic anhydride, hexahydrophthalic anhydride, pyromellitic anhydride, methylated maleic adducts of phthalic anhydride, dodecenyl succinic anhydride, dichloromaleic anhydride, tetrachlorophthalic anhydride, chlorendic anhydride, pyromellitic dianhydride, dimethyl- maleic anhydride, n-butylmaleic anhydride, phenylmaleic anhydride and bromophenylmaleic anhydride.
• Suitable polyhydric compounds include the alcohols, phenols, glycols, alkylene oxides, as well as mixtures and adducts thereof.
• Typical polyhydric compounds are glycerol, Bisphenol A, pentaerythritol, ethylene glycol, propylene glycol, and neopentyl glycol.
• the unsaturated polyesters may be further modified as is customary e.g. by reaction with other monomers.
• Suitable unsaturated polyesters may be made by any known technique wherein polyesterification of polycarboxylic compounds with polyhydric compounds is achieved, with or without . azeotropic distillation, using either the batch-fusion, batch-solvent or continuous process.
• polyesters having a phenolic component i.e., a bisphenol as a reactant, are very useful because of the improvement in heat deflection temperatures.
• Preferred unsaturated polyesters are prepared by esterifying a glycol with a polycarboxylic acid or acid anhydride.
• the polycarboxylic acid is orthophthalic or isophthalic acid.
• the unsaturated polyester and vinyl ester resins may be mixed with one or more compatible unsaturated monomers.
• monomers include, among others, aromatic compounds such as styrene, alpha-methylstyrene, dichlorostyrene, vinyl naphthalene, and vinyl phenol, unsaturated esters, such as acrylic and methacrylic esters, vinyl acetate, vinyl benzoate, vinyl chloroacetate, vinyl laurate, unsaturated acids, such as acrylic and alpha-alkylacrylic acids, butenoic acid,, and allylbenzoic acid, and vinylbenzoic acid, halides, such as vinyl chloride and vinylidene chloride, nitriles, such as acrylonitrile and methacrylonitrile, diolefins, such as butadiene, isoprene and methylpentadiene, esters of polycarboxylic acids, such as diallyl phthalate, divinyl succinate, diallyl maleate, diviny
• the weight ratio of unsaturated polyester or vinyl ester resin to unsaturated monomer will be in the range 100:0 to 20:80, preferably 95:5 to 30:70 and advantageously 80:20 to 50:50.
• Especially preferred unsaturated comonomers are the aromatic unsaturated compounds such as styrene, vinyl toluene and divinyl benzene.
• the polyester or vinyl ester resin composition contains styrene, the weight ratio of polyester or vinyl ester resin to styrene being in the range.80:20 to 50:50.
• the free-radical initiator may conveniently be an organic peroxide or an azo compound.
• free-radical initiators include organic peroxides, such as benzoyl peroxide, tertiary butyl hydroperoxide, ditertiary butyl peroxide, hydrogen peroxide, potassium persulphate, methyl cyclohexyl peroxide, cumene hydroperoxide, acetyl benzoyl peroxide, tetralin hydroperoxide, phenylcyclohexane hydroperoxide, tertiary butylisopropylbenzene hydroperoxide, tertiary butyl- peracetate, tertiary butylacetate, tertiary butyl perbenzoate, ditertiary amyl perphthalate, ditertiary peradipate, tertiary amyl percarbonate, and mixtures thereof; and azo compounds such as 2,2'-azo-bis-isobut
• catalysts include the diaroyl peroxides,tertiary alkyl hydroperoxides, alkyl peresters of percarboxylic acids and particularly those of the above-noted groups which contain no more than 18 carbon atoms per molecule and have a decomposition temperature below 125°C.
• the amount of free radical initiator will be a curing amount, conveniently from about 1% to about 15% by weight based on the unsaturated polyester or vinyl ester composition.
• the free-radical initiator is a peroxide, advantageously methyl ethyl ketone peroxide or cumene hydroperoxide.
• the unsaturated polyester or vinyl ester resin composition may additionally contain one or more modifiers such as driers (e.g. cobalt-naphthenate), plasticizers, stabilizers, extenders, oils, resins, tars, asphalts, pigments, reinforcing agents or thixotropic agents.
• driers e.g. cobalt-naphthenate
• plasticizers e.g. cobalt-naphthenate
• stabilizers e.g. cobalt-naphthenate
• extenders e.g. cobalt-naphthenate
• Fly ash is derived as a by-product of the firing of coal. It will be appreciated that because of the differences in coal sources, coal compositions, as well as coal-firing equipment and techniques and firing practices in the industry, the physical properties, chemical compositions and pozzolanic activity of the fly ashes will vary markedly. The extent and rate of pozzolanic reaction involving fly ashes is apparently a function of several factors, including the quantity of lime, cement, total silica and/or alumina in the fly ash. For example, DOT report No. FHWA-IP-76-16, states that fly ashes having large amounts of free lime as indicated by CaO content tend to be very reactive and probably exhibit some degree of self-hardening. U.S. Patent No.
• 4,210,457 contains details of typical chemical analyses of a number of types of fly ash. While the activity of the several fly ashes varied somewhat, no fly ash was found that was inoperable in the present compositions. It will be appreciated by the man skilled in the art that he should vary the content and the source of the fly ash to optimize the properties of the curable polymer concrete compositions commensurate with his end use objectives.
• the aggregate composition will contain 5% to 50% by weight of fly ash.
• aggregate compositions having fly ash contents in the range 10% to 25% by weight of the aggregate compositions have been found to give very good results.
• At least part of the balance of the aggregate composition is sand. It is generally preferred for the sand to be sand derived from the crushing of silica materials such as rock. In other words, the sand has been obtained as a fractured product and exhibits an irregular and somewhat sharp feel. This sand is required in conventional hydraulic concretes and mortars to impart the necessary structural strength.
• the so-called "beach" sand which has been uniformly rounded by the wind and/or water action, in general, produces poor physical properties in hydraulic concretes and conventional PC compositions; however, such sands, while not as good as fractured sand, can be used, alone or in blends with fractured sands, in the present compositions to give good physical properties not exhibited by conventional PC compositions.
• sand In mechanical analysis of soil, sand,according to international classification, has a size between 0.02 mm and 2.0 mm (see definition of sand in Chambers "Dictionary of Science and Technology", Edinburgh 1976).
• sand In preferred aggregate compositions, of the non-fly ash balance of the aggregate composition, at least 35% by weight is sand of particle size less than 1.19 mm.
• the aggregate composition may include other materials such as glass fibres or mats; metal fibres, staples, bars, mats or mesh; polymeric materials such as rubber and plastics, including expanded polymers; expanded mica; and crushed stone and gravel components having particle sizes greater than those of sand (i.e. greater than 200 mm) (e.g. up to about 3.8 cm).
• gravel components greater than those of sand may form up to 50%, preferably up to 25%, by weight of the aggregate composition.
• the aggregate composition may advantageously contain up to 25% by weight of an insulating material such as expanded mica.
• the aggregate composition preferably includes metal fibres, staples, mats or mesh, e.g. up to 10% by weight of steel fibres or staples.
• the invention also provides a process for preparing an article which comprises mechanically mixing together components of a curable polymer concrete composition of the invention, moulding the resulting composition, alone or in association with a substrate, and curing the moulded composition at a temperature in the range 0°C to 200 C, preferably 20°C to 100°C.
• an article comprising a cured moulded polymer concrete composition of the invention, alone or in association with a substrate.
• Such articles include pipes, metallic or non-metallic pipes coated internally and/or externally with a cured polymer concrete composition, laminated structures, building panels, armour plating, bridge deck and dam and spillway overlays.
• Vinyl Ester Resin A is a vinyl ester resin-styrene blend containing 62.5 parts by weight of a vinyl ester prepared by reacting one mole of a glycidyl polyether of 2,2-bis(4-hydroxyphenyl)propane having an epoxy equivalent weight of about 375 and an average molecular weight of about 920 with two moles of methacrylic acid in the presence of an esterification catalyst, and 37.5 parts by weight of styrene.
• Polyester A is an isophthalic/glycol polyester (Reichold, "Polylite” 31-439) ("POLYLITE” is a registered Trade Mark).
• This example illustrates the fabrication of pipe using a vinyl ester resin-based polymer concrete composition.
• the mould was mounted between two flat vertical plates, grooved for the cardboard mould, which were connected to each other by equal length rods and driven by a variable speed motor. After the polymer concrete composition was displaced into the cardboard drum, the drum was revolved at approximately 300 rpm for 60 minutes. The mould was then removed from the grooved flat plates and the pipe stripped from the mould. The pipe was then post-cured at about 93°C (200 0 F) for one hour, after which it was removed and allowed to cool. The pipe was tested according to ASTM C-497, "External Load Crushing Strength Test by the Three Edge Bearing Method". The crushing strength for the polymer concrete pipe averaged 5600 pounds per linear foot (8330 kg/m), which is almost three times the crushing strength of a concrete pipe having the same diameter and wall thickness.
• This example illustrates the resistance to projectiles of vinyl ester resin-based polymer concrete compositions.
• Example I The procedure of Example I was repeated wherein a polymer concrete composition containing 85% aggregate, which contained 80% sand and 20% fly ash, and 15% Vinyl Ester Resin A (containing 2% by weight of MEKP based on the Vinyl Ester) was prepared. To this composition were added 6% by weight based on the composition of steel deformed end fibres (conventional concrete hooked end staples having an average size and gauge of 30 mm long and 0.4 mm diameter) and the reinforced mixture moulded into blocks 3" x 6" x 12" (7.5 cm x 15 cm x 30 cm) and cured at 20 0 C for 60 minutes and then postcured at 95 0 C for 30 minutes. The cured blocks were taken to a firing range.
• steel deformed end fibres conventional concrete hooked end staples having an average size and gauge of 30 mm long and 0.4 mm diameter
• the instant reinforced polymer concrete blocks were barely chipped on the surface by either projectile.
• This example illustrates the use of non-fractured sand in vinyl ester resin-based polymer concrete compositions.
• Example I The procedures of Example I were essentially repeated wherein various polymer concrete compositions were prepared using "contaminated” rounded sand obtained from Saudi Arabia, as well as conventional "fractured” sand.
• compositions are as follows (all compositions contained 2% by weight of methyl ethyl ketone per- oxide (MEKP) and 0.5% by weight of cobalt naphthenate based on the weight of Vinyl Ester Resin A):
• compositions were cured at room temperature for 1 hour and then post-cured at 95°C for 30 minutes.
• the flexural and compressive strength of the cured compositions were then determined and the data are presented in Table I.
• This example illustrates the reduced shrinkage exhibited by vinyl ester resin-based polymer concrete compositions.
• Sand/gravel mixture used in the compositions had the following composition:
• the shrinkage should be ⁇ 0.25% to avoid cracking in PC coatings which are exposed to water, especially hot water.
• PC compositions which are used in bridge decks, pipe linings, dam spillway overlays, etc. should exhibit a shrinkage of ⁇ 0.25% to prevent cracking and delamination.
• Vinyl ester resin-based polymer concrete compositions were found to be suitable for the following applications:
• the pipe may be fabricated by well-known techniques. wherein a substrate (carrier) such as a metal pipe is coated with the present composition and cured.
• a substrate such as a metal pipe
• the substrate layer may be coated with a composition such as a resin, an epoxy resin, or it may be treated with one or more compositions to enhance the adhesion of the instant vinyl ester polymer concrete compositions to the substrate.
• one or more layers i.e., a laminated structure, may be employed.
• a metallic pipe may be coated with a glass, plastic and/or resinous coating before the application of the instant vinyl ester polymer concrete compositions.
• substrate as used herein is deemed to mean any layer, however thin, including coating layers, other than a layer of the instant polymer concrete composition.
• a reinforcement material which may be metallic or non-metallic, in the polymer concrete is useful, for example, glass or plastic (nylon) fibres, webs or mats may be incorporated therein.
• the vinyl ester is a 50:50 blend of vinyl ester and styrene, said vinyl ester being prepared by first reacting 2 moles of methacrylic acid and one mole of a diglycidyl polyether of 2,2-bis(4-hydroxyphenyl)propane having a WPE of about 180, an average molecular weight of about 360 and then esterifying about 10% of the secondary hydroxyl groups with maleic anhydride.
• This example illustrates the preparation of polyester-based polymer concrete compositions with both non-fractured sand and fractured sand.
• compositions were prepared by mixing the various components together and test speciments prepared by curing at room temperature for 1 hour and post-curing at 95 0 C for 30 minutes (all compositions contained 2% by weight of methyl ethyl ketone peroxide (MEKP) and 0.4% by weight of cobalt naphthenate, based of the weight of Polyester A).
• MEKP methyl ethyl ketone peroxide
• compositions were cured at room temperature for 1 hour and then post-cured at 95 0 C for 30 minutes.
• the flexural and compressive strength of the cured compositions were then determined and the data are presented in Table II.
• composition AD When Composition AD is applied as a pipe lining via centrifugal casting methods and cured, the resulting lining exhibits good chemical resistance.
• Example VII The procedures of Example VII were essentially repeated wherein Polyester A is replaced with an equivalent amount of the following polyesters:
• the impact resistance is improved by the addition of metallic reinforcement such as metal staples to the composition of Example VII. Likewise, the replacement of about 20% of the sand with fractured gravel improved the impact resistance.

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• Materials Engineering (AREA)
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• Organic Chemistry (AREA)
• Macromonomer-Based Addition Polymer (AREA)
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Citations (5)

• 1982
  • 1982-03-25 DE DE8282200372T patent/DE3273103D1/de not_active Expired
  • 1982-03-25 CA CA000399347A patent/CA1171191A/en not_active Expired
  • 1982-03-25 EP EP19820200372 patent/EP0062373B1/de not_active Expired
  • 1982-03-31 AR AR28897582A patent/AR226262A1/es active
  • 1982-04-01 DK DK148482A patent/DK148482A/da not_active Application Discontinuation
  • 1982-04-01 AU AU82268/82A patent/AU546279B2/en not_active Ceased
  • 1982-04-02 ES ES511104A patent/ES511104A0/es active Granted
  • 1982-04-02 NZ NZ20022682A patent/NZ200226A/xx unknown
  • 1982-04-02 NO NO821120A patent/NO821120L/no unknown

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